Tool Edge Radius Research Articles

Inverse Identification of Constitutive Model for GH4198 Based on Genetic-Particle Swarm Algorithm.

A precise Johnson-Cook (J-C) constitutive model is the foundation for precise calculation of finite-element simulation. In order to obtain the J-C constitutive model accurately for a new cast and forged alloy GH4198, an inverse identification of J-C constitutive model was proposed based on a genetic-particle swarm algorithm. Firstly, a quasi-static tensile test at different strain rates was conducted to determine the initial yield strength A, strain hardening coefficient B, and work hardening exponent n for the material's J-C model. Secondly, a new method for orthogonal cutting model was constructed based on the unequal division shear theory and considering the influence of tool edge radius. In order to obtain the strain-rate strengthening coefficient C and thermal softening coefficient m, an orthogonal cutting experiment was conducted. Finally, in order to validate the precision of the constitutive model, an orthogonal cutting thermo-mechanical coupling simulation model was established. Meanwhile, the sensitivity of J-C constitutive model parameters on simulation results was analyzed. The results indicate that the parameter m significantly affects chip morphology, and that the parameter C has a notable impact on the cutting force. This study addressed the issue of missing constitutive parameters for GH4198 and provided a theoretical reference for the optimization and identification of constitutive models for other aerospace materials.

Unraveling the complex interplay between elastic recovery, contact pressure, and friction on the flank face of the micro tools via plunging-type testing

A good understanding of the interplay between the cutting tool edge radius, elastic recovery, friction, and contact pressure is essential for better modeling of ploughing forces during micro-scale cutting. This study conducts plunging tests on an ultra-precision CNC with engineered tungsten carbide cutting tools on commercially pure titanium alloy. The cutting tool edge radius is prepared to be around 3.5–4 μm, which resembles those cutting tools used in micro scale machining. During plunging tests, the micro cutting tool is given a sinusoidal movement with an amplitude close to edge radius of the tool as the work material is rotated at a constant speed. The residual depth profiles of the webs corresponding to the commanded depths were investigated in detail to identify elastic recovery rate. The cutting and thrust force measurements during plunging experiments together with identified elastic recovery rate was employed in an analytical model of micro scale machining to obtain the variations of contact pressure and coefficient of friction as a function of commanded depth. Due to the scale of the experiments that were performed, the effects of surface topography of the cutting tool and possible alignment errors are also considered in the analytical model. A linear relationship between the contact pressure and elastic recovery has been identified during ploughing-dominated machining conditions for the work material and the cutting tool pair considered in this study. The proposed experimental technique is shown to be promising in terms of modeling ploughing forces during micro-scale cutting.

Molecular dynamics simulation of the effect of tool parameters on nano-cutting of polycrystalline γ-TiAl alloys

As one of the most promising lightweight high-temperature structural materials in the future, the surface quality of γ-TiAl alloys has a great influence on the performance of the workpieces, and the tool parameters are an important factor affecting the machining results. In this study, molecular dynamics simulations of the nano-cutting process of polycrystalline γ-TiAl alloys with different tool parameters were carried out. The results show that increasing the tool rake angle and decreasing the tool edge radius within a certain range helps to reduce the average cutting force, cutting force fluctuation, cutting temperature, and stabilize the cutting process, while the change of the tool clearance angle has less influence on the cutting process. In contrast, negative rake angle cutting is more likely to produce grain rotation and grain boundary steps in the processed substrate and increase the processed surface roughness than positive rake angle cutting; increasing the tool rake angle within a certain range will weaken the elastic recovery effect of the substrate. During cutting at a positive rake angle, whether a portion of the substrate is prone to slip toward the surface of the substrate, thereby reducing the surface quality, depends on the relative state of grain orientation and force applied in the substrate.

Evaluation of tool wear during micro-milling of ultrasonically assisted abrasive peened Ti-6Al-4V

When a cutting tool shears through a workpiece, the interaction causes wear of the tool which is based on relative hardness, surface characteristics of the tool and the workpiece, cutting environment and thermal behaviour at the work/tool interface. In this study, wear of a micro-end milling tool is investigated while milling of as-received and peened work material (in this case, Ti-6Al-4V). The peening is performed with the help of an in-house developed ultrasonic cavitation process. The process excites the abrasives suspended in the cavitating medium, which impart on the work surface and induce compressive residual stress and uniform grain refinement. As the cutting process advances, a built-up is formed more rapidly in the as-received workpiece, leading to higher cutting forces and earlier chipping of the cutting edge. Under the peened conditions, it is found that the increase in tool edge radius and flank wear width reduce by 50 % and 54 % respectively compared to the as-received one. Additionally, peening-induced grain refinement leads to a 26 % decrease in surface roughness of the machined surface and inhibits burr formation by 60 %. A tool wear chipping model is employed to predict the tool diameter, cutting edge radius and flank wear width of the worn tool. Results show that the magnitude of flank wear, edge radius of worn tool and tool diameter deviate from experiments by 15.2 %, 14 % and 13 % respectively.

Influence of tool flank wear considering tool edge radius on instantaneous uncut chip thickness and cutting force in micro-end milling

Influence of tool flank wear considering tool edge radius on instantaneous uncut chip thickness and cutting force in micro-end milling

Numerical and experimental investigation of direct rapid tooling for sheet metal forming using selective laser sintering

The rapid tooling approaches were most sought after for the low-volume production of sheet metal parts within a short duration. This study presents an investigation of direct rapid tools produced with Selective Laser Sintering (SLS) for sheet metal forming. SLS is one of the widely used additive manufacturing techniques to produce polymer parts. The ability to form the sheet metal components using SLS direct rapid tools was assessed through cup drawing from aluminium blanks. A full factorial experiment was formulated to design the tools by varying the punch radius, die radius and draw ratio. The tools were fabricated with SLS using glass bead - filled polyamide material (PAGF) and finite element analysis was employed to study the stress distribution. The stress concentrations were observed at the tool edge radius, yet the PAGF tools sustained the load from the cup drawing process. The inspection of the PAGF tools and drawn cups shows that they are sensitive to the edge radius and draw ratio. Wear at the edge radius was evaluated in terms of percentage deviation from the initial radius. While the designed dimension of the edge radius is a significant factor affecting respective tool edges, the die edge wear was also influenced by the draw ratio. Both the formed parts and the tools exhibit geometrical variations localised to the forming edges and demonstrate good repeatability even up to 200 draw cycles.

Influence of tool-edge radius on the nano-cutting process of non-continuous surfaces in single-crystal silicon

Pore deformation and damage are caused by the compression of the cutting tool during the machining of porous materials. Tool-edge radius is a key factor in the nano-cutting of pores and significantly influences the resulting deformation and damage. In this paper, the molecular dynamics simulations were conducted to investigate nano-cutting process of the non-continuous surface in single-crystal silicon. Surface morphology, pore wall deformation, cutting forces, and subsurface damage were calculated and discussed under different tool-edge radii. The results indicated that the change of the tool-edge radius greatly affect the machining quality of non-continuous surface. Cutting forces and accumulated material above the pores increase with increasing tool-edge radius, and the side of the tool entering the pore is more susceptible to damage than the opposite side. Additionally, normal force was identified as the primary cause of damage on the side of the tool entering the pore. The longitudinal damage depth on the side of the tool entering the pore increases with the tool-edge radius. Comprehensive analysis of material distribution, pore wall deformation and damage indicates that a smaller tool-edge radius is more conducive to pore processing.

Fabrication of polycrystalline diamond micro-milling cutter with different grain sizes by picosecond laser

Polycrystalline diamond (PCD) is an excellent material for machining micro-tools due to its high hardness and wear resistance. However, the diameter of micro-milling tools is generally required to be less than 500 μm. When preparing micro-milling tools with a large aspect ratio, the processing load introduced by traditional grinding methods is easy to cause tool fracture. Therefore, a composite structure of carbide tool holder and diamond tool head is proposed in this paper. A technique of picosecond laser machining PCD micro-milling tool was studied, and the overall manufacturing process of tool blank preparation, nanosecond laser roughing and picosecond laser finishing was formed. A two-dimensional ablation mathematical model for tangential machining of PCD with a multi-pulse picosecond laser was established, and experiments verified the reliability of the mathematical model. In addition, the effects of picosecond laser pulse pitch, pulse energy, and track spacing on the surface quality of PCD materials with different particle sizes and cutting edge radius were studied by orthogonal experiments. The results showed that after picosecond laser processing, the surface roughness (Sa) of PCD with a particle size of 2 μm was the best, which can reach 0.33 μm, and the cutting edge radius of PCD micro-milling tool with a particle size of 25 μm was the smallest, which can get 1.67 μm. Using the optimized picosecond laser parameters, the high-sharpness single-edge micro-milling cutters with different particle sizes PCD with a diameter of 100 μm, aspect ratio greater than 3, and a cutting edge radius less than 3 μm were successfully fabricated.

Elliptical vibration chiseling: a novel process for texturing ultra-high-aspect-ratio microstructures on the metallic surface

Highlights Elliptical vibration chiseling is proposed based on a game-changing process principle for the high-efficient texturing of ultrahigh-aspect-ratio surface microstructures. Uniformed microstructures with an aspect ratio of 2–12 in the spacing scale of 1–10 μm have been successfully fabricated using elliptical vibration chiseling. The developed process model of elliptical vibration chiseling has been verified by the measured results of the microstructures’ geometric parameters. An inclined elliptical trajectory of tool vibration is more suitable for elliptical vibration chiseling than the standard elliptical trajectory. The deterministic process effects on the surface generation of microstructure in elliptical vibration chiseling have been demonstrated.

Analysis of material removal mechanism in nanoscale machining of copper

In the current study, molecular dynamics modeling and simulation are carried out to analyse mechanisms in tool-workpiece interaction in nanoscale cutting. Various combinations of a/ r ratios for constant r ( r = tool edge radius and a = uncut chip thickness) are considered and different crystal orientations of the workpiece specimen are employed in the nanoscale cutting model. From the simulation, material anisotropy behavior is observed during the nanoscale cutting of copper material. Analysis at the molecular scale reveals that the crystal orientations family {1 1 0}<1 0 0> is hard to machine and the family of crystal planes {1 1 1}<1 1 0> is easiest to cut. While comparing in different crystal planes and directions, it was noticed that the material deformation in nanoscale machining takes place only in slip directions, that is, <1 1 0> family of directions. It is also found that as the uncut chip thickness is decreased, the cutting mechanism changes from shear plane cutting to plowing to sliding in Cu.

FE parametric evaluation of macro-to-microscale dry milling for sustainable manufacturing of aerospace alloys

Micro-end-milling of energy-efficient materials has gained prime significance in advanced manufacturing due to their excellent machining characteristics. Numerous experimental and numerical studies have been conducted to establish the optimum parameters of the micro-end-milling process. Because of the complex interaction at the tool-burr interface that involves high material strain rates, this study investigated an extensive parametric sensitivity analysis to evaluate the reliability of numerical simulations. The numerical simulations of AA2024 and Ti6Al4V alloy micro-end-milling are performed in Abaqus/Explicit using the thermo-viscoelastic Johnson-Cook damage model. The parametric sensitivity analysis of both materials is compared, and the burr morphologies are analyzed with changing material characteristics. Tool-burr interface temperature, cutting reaction forces, material plastic strain, and stresses are evaluated to analyze the effect of the change in material characteristics with cutting parameters. Computations are performed at different cutting speeds, tool edge radii, cutting feeds, and contact friction to analyze their effect on chip stress, temperature, material strain, and the tool's thrust force. Feed and contract friction demonstrated pronounced effects on the chip-tool interface temperature compared to the contact friction for both types of materials. The computational results are verified with the experimental data.

Investigation of the tool flank wear influence on cutter-workpiece engagement and cutting force in micro milling processes

Cutting force modeling is essential for comprehending the dynamic mechanics of the micro-milling process. Accurate calculation of the cutter-workpiece engagement is crucial for predicting cutting force accurately. This study proposes an accurate analytical model of cutter-workpiece engagement that comprehensively incorporates tool flank wear, tool edge radius, and tool runout for predicting cutting forces in the micro-milling process. Based on the actual tool radius model, which takes into account tool flank wear and tool edge radius, a fast real-time online method for accurately calculating the entry and exit angles is presented. This method involves the trochoidal trajectories of the current cutting edge and all passing cutting edges from the previous cycle under the influence of tool runout. Then the cutter-workpiece engagement is determined. Based on this, the cutting force is predicted combined with instantaneous uncut chip thickness and cutting force coefficients considering tool flank wear and tool runout. Through micro-end milling experiments, the validity of the cutting force model is confirmed. The statistical analysis of the predicted cutting forces further demonstrates the effectiveness of accounting for the impact of tool flank wear on the cutting forces throughout the entire micro-milling process. Through case analysis, it is concluded that tool flank wear leads to increased cutter-workpiece engagement and significantly affects the cutting forces in three directions. This work could offer a theoretical foundation and practical guidance for predicting tool life and controlling surface quality during the machining process.

Effect of arc-deposited diamond-like carbon (DLC) coating thickness on friction and size effects in high-speed micromilling of Ti6Al4V

Diamond-like carbon (DLC) can be considered one of the frontline coating materials for high-speed cutting tools owing to both abrasion resistance and solid lubricant properties. However, coating thickness increases the edge radius of the micro tools, which may result in adverse rubbing and plowing that need to be investigated. In this work, DLC coatings of 440, 640, and 1160 nm thicknesses with a ∼250 nm Cr interlayer are deposited on WC micro-end mills using a cathodic-arc system. DLC-coated surfaces exhibited enhanced tribological and mechanical properties compared to uncoated surfaces. Among the DLC-coated micro-end mills, the DLC-640 nm coated tool outperformed, manifesting the best machining performance by reducing friction and size effects together.

The Influence of Tool Geometry Parameters on Thermo-Mechanical Loads and Residual Stresses Induced by Orthogonal Cutting of AA6061-T6: A Numerical Investigation

The residual stresses state that a mechanical part obtained after machining is a crucial factor that impacts its in-service performance. This stress state is influenced by the thermomechanical loads exerted on the parts during the machining process, which are, in turn, determined by the tool parameters, process, and machining conditions. The aim of the present research was to anticipate how the cutting tool’s edge radius, rake angle, and clearance angle would affect the forces, temperature, and residual stresses induced while orthogonally cutting aluminum AA6061-T6. To achieve this, two-dimensional DEFORM™ software was utilized to develop a finite element model. The residual stresses trend results obtained demonstrated that rake angles of 0° and 17.5–20° values with a small edge radius (5 to 10 µm) and clearance angles of 7 and 17.5° values gave higher compressive stresses. The obtained simulated results were in good agreement with the experiments. The cutting forces, the temperature, and the maximum and minimum machining-induced residual stresses were found to be influenced more by the tool edge radius and the tool rake angle. The influence of the clearance angles on the above-mentioned machining responses was the least. Residual stresses can have a significant impact on the in-service performance of machined parts. The obtained results will help engineers select or design tools that promote a desired surface integrity during machining. This task is not obvious in practice because of difficulties in measuring residual stresses and also because the machining parameters and the tool geometry parameters have different and opposite impacts on thermo-mechanical loads, productivity, and on machining induced residual stresses.

Investigation of the cutting-edge radius size effect on dynamic forces in micro end milling of brass260

Rapid increases in the number of industries that need a sub-micron surface finish on 3D micro/meso technological innovation parts are being seen. Due to the high rotating speeds of activities, chatter behaviour also occurs during micro-cutting. Changes in bearing stiffness, gyroscopic effects, and misalignment are only some of the factors that need to be considered while studying the spindle's dynamics. By regulating the movement of the cutting edge, the cutting action may be made more consistent. The structure of the tools also affects the machine's dynamics. Since the modes of different machine-tool components interact with one another, the dynamics of the tool tip are affected. In this research, we consider a model of a micro spindle system to enhance machining accuracy. Timoshenko beam theory is used to account for shear deformation and rotational inertia effects due to the short and thick beam-type designs of each component of the micro tool. A detailed dynamical model of the moving micro end mill is created using an extended form of Hamilton's Principle. A two-degree-of-freedom model of the micro-milling process considers the modal dynamic properties of the tool-holder-spindle assembly and the micro-milling cutting forces. A three-dimensional finite element model of the system is built, and its dynamic response is gathered, to validate the full order finite element approach. Cutting force coefficients are then modelled as a function of instantaneous uncut chip thickness, which is principally affected by the tool edge radius and feed per tooth at different radial immersion depths.

A Novel 2D Micromilling FEM simulation strategy to optimize the flow stress law of IN625

The products miniaturization tendency of the last years led to an acceleration of micromilling process development. Considering the high-quality requirements, a deep knowledge of this operation, concerning ploughing-shearing transition, tool run-out, and tool edge radius effects, is mandatory, especially when machining difficult-to-cut materials. For this reason, this paper introduces a novel 2D micromachining Finite Element Method simulation strategy for micromilling forces evaluation, when cutting IN625. The major output of this technique consists in the computation of an optimized flow stress law, suitable for the simulation of high-speed machining. Particle Swarm Optimization method was employed for optimizing the flow stress parameters by comparing the cutting force predicted by an analytical model previously calibrated on experimental data, providing good agreement. This strategy permits the micromilling process predictive analysis, avoiding costly optimization experimental tests.

Analysis and prediction of residual stresses based on cutting temperature and cutting force in rough turning of Ti–6Al–4V

Turning is a typical machining process, which is widely used in the manufacturing process of parts. The residual stress introduced by turning has a significant influence on the mechanical properties, fatigue performance, and service safety, and is one of the key factors affecting the fatigue life of parts. Conventional residual stress prediction models based on cutting parameters cannot consider all the influencing factors of turning and are strongly dependent on the specific cutting environment and tool, so they have limitations. Therefore, a residual stress analysis and prediction method based on cutting temperature and cutting force is proposed in this paper for the rough turning process of Ti–6Al–4V. Firstly, the sensitivity analysis of turning residual stress is carried out on eight cutting variables to determine the key cutting variables affecting the residual stress. Subsequently, the influence of the above key variables on residual stress is analyzed from the perspective of cutting temperature and cutting force. Finally, the residual stress prediction model based on cutting temperature and cutting force is established. The results show that the three variables that have the greatest influence on residual stresses are friction coefficient, tool edge radius, and cutting speed. The friction coefficient and tool edge radius affect the thickness of the residual stress layer. The cutting speed has little effect on the thickness of the residual stress layer, but increasing the cutting speed will lead to the transformation of residual stress to tensile stress. The relative error between the predicted value and the simulated value of residual stress is less than 6%, indicating that the prediction model has high accuracy and can effectively predict the residual stress. The prediction method proposed in this paper is not limited by the specific turning condition and provides a new perspective for the analysis and prediction of turning residual stress.

Generic Cutting Force Modeling with Comprehensively Considering Tool Edge Radius, Tool Flank Wear and Tool Runout in Micro-End Milling.

Accurate cutting force prediction is crucial in improving machining precision and surface quality in the micro-milling process, in which tool wear and runout are essential factors. A generic analytic cutting force model considering the effect of tool edge radius on tool flank wear and tool runout in the micro-end milling process is proposed. Based on the analytic modeling of the cutting part of the cutting edge in the end face of the micro-end mill bottom, the actual radius model of the worn tool is established, considering the tool edge radius and tool flank wear. The tool edge radius, tool wear, tool runout, trochoidal trajectories of the current cutting edge, and all cutting edges in the previous cycle are comprehensively considered in the instantaneous uncut chip thickness calculation and the cutter-workpiece engagement determination. The cutting force coefficient model including tool wear is established. A series of milling experiments are performed to verify the accuracy and effectiveness of the proposed cutting force model. The results show that the predicted cutting forces are in good agreement with the experimental cutting forces, and it is necessary to consider tool wear in the micro-milling force modeling. The results indicate that tool wear has a significant influence on the cutting forces and cutting force coefficients in the three directions, and the influences of tool wear on the axial cutting force and axial force coefficient are the largest, respectively. The proposed cutting force model can contribute to real-time machining process monitoring, cutting parameters optimization and ensuring machining quality.

Fabrication of high aspect-ratio aspheric microlens array based on local spiral diamond milling

Ultraprecision mold machining combined with precision glass molding is the most promising technology for the mass production of glass microlens arrays (MLAs). However, fabricating an MLA with a high aspect-ratio (AR) (ratio of height to aperture), submicron scale profile accuracy, nanoscale surface finish, and good consistency remains a considerable challenge. A local spiral diamond milling (LSDM) method is proposed to generate a high AR MLA on a nickel-phosphorous (Ni-P) plated mold. A spiral toolpath generation algorithm that considers the tool edge radius and performs profile error (PV) compensation is developed. Each lenslet at any local position can be precisely machined by controlling the servo motions of the three translational axes. Then, the entire MLA can be generated by shifting the toolpath to go through the centers of all lenslets according to the MLA layout. The tool parameters are optimized to avoid local and global tool interference during machining. The generated toolpath provides steady slide axis movements to avoid dramatic changes in cutting speed and acceleration. An MLA with an AR of 0.166 is fabricated. The results show that the fabricated mold and the molded lenses have a profile accuracy (PV) of less than 1 μm and a surface roughness (Ra) of less than 14 nm. The cross-sectional profiles indicate that the fabricated MLA has high machining consistency.

Accurate measurement of cutting-edge radius on a single-crystal diamond tool

Single-crystal diamond (SCD) tools are hard and can maintain a uniform sharp cutting edge and hence used in ultraprecision machining of optics. The tools typically have edge radii in the range of 10-100 nm. Direct measurement of the cutting-edge radius on the SCD tool accurately in the order of tens of nanometers using a scanning electron microscope (SEM) is not possible and arduous using an atomic force microscope (AFM). In this study, we have demonstrated a more accurate edge reversal technique to measure the SCD tool’s cutting-edge radius. A nano indent is made using the SCD tool on two polished pure copper blocks held together in a precise vise. After the nanoindentation, the copper blocks are separated, and the cross-section profile of the indentation mark, a replica of cutting-edge geometry, is observed in an SEM. A fitted circle on the indentation profile is used to obtain the edge radius. Due to the elastic recovery in the material, the indentation profile geometry changes slightly, and the radius measured from the SEM image is not the same as the actual tool radius of the SCD tool. We performed finite element method (FEM) simulations to quantify the amount of elastic recovery and calculate the elastic recovery factor for a given SCD tool geometry as a function of indentation depth and edge radius. From the simulation results, we found the error due to elastic recovery effect in edge radius measurement is only 10%. Due to the stick-slip condition and high stress concentration factor at the cutting edge of the tool, material pull-out is observed at the middle of the cutting mark on the substrate but at the ends of cutting mark on the substrate material was negligible. In this method, compared to the previous literature work the three primary sources of errors, elastic recovery effect, convolution effect of AFM tip, and material pull-out are eliminated. Hence, this method provides a more accurate measurement of the edge radius and can be adopted by research labs, universities, and industries having ultra-precision machining facilities without needing a special purpose SCD tool edge radius characterization facility.